PERTANDINGAN WORLDSKILLS MALAYSIA KATEGORI BELIA · PDF filepertandingan worldskills malaysia...

Pertandingan WSMB Belia 2015 Ke-24

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PERTANDINGAN WORLDSKILLS MALAYSIA KATEGORI BELIA (WSMB)

TAHUN 2015

( ELECTRONICS )

TECHNICAL DESCRIPTION

JABATAN PEMBANGUNAN KEMAHIRAN

KEMENTERIAN SUMBER MANUSIA


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This document contains information about the standards required to compete in this skill competition and the assessment principles, methods and procedures that govern the Electronics trade in WorldSkills Malaysia Belia competition 2015. If any doubt from this document to the competition rules and regulation by secretariat, the rules and regulation of the secretariat will take precedence. 1. Standards specification

Adapting WorldSkills standards specification as below:


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2. Competition stage There is TWO (2) stages for Electronics trade in WSMB 2015 which is pre – qualifying and final stage. All participants are required to compete and pass the pre – qualifying stage before going through the final stage. Numbers of finalist is between 8 to 12 participants depending on the overall achievement of the trade and agreement from technical secretariat meeting.

3. PRE – Qualifying stage 3.1 Completion of skills assessment specification

a. Theory Test: 1 Hour

This is 40 objective questions. Participants must answer the entire question in an answer sheet provided. Topic covered: - Quantities and Units - Analog to Digital - Numbers System & Codes - Logic gates - Testing & Troubleshooting - Basic Analog Electronics

Significance: Electronics fundamental knowledge.

b. Board Assembly & Measurement: 2 Hour

Assemble the component onto provided printed circuit board. Test the board functionality and carry out some measurement to prove the functionality. Significance: Soldering & Desoldering skills, troubleshooting skills, equipment usage, interpret signal.

c. Circuit Reverse Engineering: 1 Hour Re - construct certain block in the circuit board by reverse engineering technique. Significance: Circuit interpretation and analyzing skills.


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3.2 Marking Procedure

Theory : 10% Board Assembly & Measurement

- Board Functionality : 10% - Component Assembly : 40% - Measurement : 10%

Circuit Reverse Engineering : 30% TOTAL : 100%

3.3 Competition Time Table Refer to appendices

3.4 Project Part List

No. Component Value Designator Quantity 1 Variable Resistor 100K R3 1 2 Capacitor 100nF C3 1

3 Polarized Capacitor 100uF C1 1

4 Resistor 10K R2 1

5 Capacitor 10nF

C4, C6, C7, C8, C9, C10, C11, C12, C13, C14, C15, C16, C17, C18, C19, C20, C21

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7 Resistor 150R R15, R16, R17, R18, R19, R20, R21 7

8 Resistor 1K R4, R5 2

9 Resistor 220R R6, R7, R8, R9, R10, R11, R12, R13, R14

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10 Resistor 330R R1 1


12 IC1 CD4013BCN U14, U16 2 13 IC2 CD4027BCN U10, U11 2


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14 IC3 CD4030CN U8 1 15 IC4 CD4071BCN U1, U4 2 16 IC5 CD4081BCN U2, U3, U5, U6 4 17 IC6 CD4511BCN U18 1 18 IC7 HCC4028BF U17 1 19 IC8 HCC4073BF U7 1 20 IC9 HCF4063BEY U13, U15 2 25 IC10 LM555CN U12 1

21 7-Segment Display HDSP-503B DS1 1

22 Voltage Regulator L7805CP U9 1

23 LED 3mm Red D1, D2, D3, D4, D5, D6, D7, D8, D9 9

24 LED 3mm Green D10 1

26 DC Jack Connector Female J1 1

27 Switch Push Button S1, S2 2

3.5 Component Layout


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4. Final stage There are 4 modules which are Hardware Design, Embedded System Programming, MFFR and Assembly. Except the assembly module, all module adapting closed question format. 4.1 Hardware Design Module

Refer to appendices

4.2 Embedded System Programming Module Refer to appendices

4.3 MFFR Module Refer to appendices

4.4 Assembly Module Refer to appendices

4.5 Marking Procedure

4.6 Competition Time-Table Refer to appendices


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5. Suggested Hand Tools brought by participants.

Bil. Senarai Bahan, Perkakas dan Peralatan

Kuantiti seorang

01 Soldering Station 1

02 Desoldering Station 1

03 Complete electronics toolbox 1

04 Multimeter Digital 1

05 Multimeter Analog 1

06 Antistatic Protection 1

07 Scientific Calculator (not advanced then FX-570MS) 1

08 Electrostatic Glove 1

09 Face Mask 1

10 Stop Watch (Optional) 1

11 Any related tools for electronics work. -

6. Notice and some Rules & Regulation

a. Solder lead to be used is lead free type. b. Mask and glove wearing during soldering work is a compulsory otherwise

participant will not be allowed to continue their work. c. Written or blank papers from outside are not allow in the competition room. d. Written or blank papers including question paper are not allowed to be carried

out from the competition room. e. All required datasheet will be provided. f. Participants are subjects to the competition laws and rules. Chief Judges may

disqualify any competitor who breaches any of the above rules.

7. Changes of Test Project Minor changes will be carried out without notice subjected to component discontinue, manufacturing error during prototype development, improving the quality and etc. Feel free to updated yourself by visiting secretariat website at www.skillsmalaysia.gov.my


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APPENDICES


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PRE-QUALIFYING STAGE TIME TABLE (Subjected to Change)

Module Time allowed (Hours) Day Theory 1 D1

Board Assembly & Measurement 2 D2 &D3 Circuit Reverse Engineering 1 D2 &D3

TOTAL HOURS 4 -

Day 1

Time Activities Hours 8.30 a.m – 9.30 a.m Registration 1

9.30 a.m – 10.00 a.m Morning Break 1/2 10.00 a.m – 11.30 a.m Welcome / General Briefing / Rules & Regulation 1 ½ 11.30 a.m – 12.00 a.m Safety Briefing 1/2 12.00 p.m – 12.30 p.m Open Discussion 1/2

12.30p.m – 2.30p.m Lunch Break 2 2.30p.m – 3.30p.m Theory 1 3.30p.m – 3.45p.m Afternoon Break 3.45p.m – 5.30p.m Familiarization 2

Day 2

Time Activities Hours

9.00 a.m – 10.00 a.m Project Briefing and Open discussion 1 10.00a.m – 10.15 a.m Morning Break 1/4 10.15a.m – 11.00a.m Workstation Preparation 3/4

11.00 a.m – 1.00 p.m Board Assembly & Measurement 2 1.00p.m – 2.30p.m Lunch Break (Quarantine Room) 1 ½

2.30 p.m – 3.30 p.m Circuit Reverse Engineering 1 3.30 p.m – 4.00 p.m Afternoon Break 1/2

Day 3


9.00 a.m – 10.00 a.m Project Briefing and Open discussion 1 10.00a.m – 10.15 a.m Morning Break 1/4 10.15a.m – 11.00a.m Workstation Preparation 3/4 11.00 a.m – 1.00 p.m Board Assembly & Measurement 2

1.00p.m – 2.30p.m Lunch Break (Quarantine Room) 1 ½ 2.30 p.m – 3.30 p.m Circuit Reverse Engineering 1 3.30 p.m – 4.00 p.m Afternoon Break 1/2


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FINAL STAGE TIME TABLE (Subjected to Change)

Module Time allowed (Hours) Day Hardware Design 6 D1 and D3

Embedded systems programming 3 D1 Assembly 3 D2 Fault finding, repair and measurement 3 D3 TOTAL HOURS 15 -

Day 0

Time Activities Hours 8.30 a.m – 9.30 a.m Registration and Briefing 1 9.30 a.m – 2.30 p.m Familiarization 4 ½

Day 1


8.00 a.m – 8.30 a.m Briefing and Open discussion on HWD – 1 & 2 ½ 8.30 a.m – 10.30 a.m Hardware design - Part 1 1 ½

11 a.m – 1.30 p.m Hardware design - Part 2 2 ½

2.30 p.m – 3.00 p.m Briefing and Open discussion on SWD ½

3.00 p.m – 6.00 p.m Embedded Software Design 3

Day 2


9.00 a.m – 10.00 a.m Briefing and Open discussion on Assembly Tasks 1

10.30 a.m – 1.30 p.m Assembly Project 3

Day 3


9.00 a.m – 10.00 a.m Briefing and Open discussion on MFFR 1

10.00 a.m – 1.00 p.m MFFR Project 3

2.00 p.m – 2.30 p.m Briefing and Open discussion on HWD - 3 ½

2.30 p.m – 4.30 p.m Hardware design - Part 3 2

Pertandingan Kemahiran Malaysia ke - 23

PERTANDINGAN WORLDSKILLS

MALAYSIA KATEGORI BELIA (WSMB) TAHUN 2015

( ELECTRONICS )

( HARDWARE DESIGN )

SOALAN PRAKTIKAL

PERINGKAT AKHIR

MASA : 6 JAM

NAMA: _______________________________________

No. KP: _______________________________________



Pertandingan Kemahiran Malaysia ke - 23

Project: Hardware Design Hardware Circuit Design: Time limit is 1 1/2 hours. Design of Printed Circuit Board: Time limit is 2 1/2 hours. Build and Test Designed Prototype: Time limit is 2 hours. INTRODUCTION

This project tests the competitor’s skill in hardware design and printed circuit board design to design the Selectable TIMER. The block diagram of the project is as shown in Figure 1 below. When the PB1 is pressed, the counter reset to 0 thus the output of DAC will be 0V. This allow the clock to be passed to the counter. The counter counts up and stops at maximum counts.

LED BARGRAPH DISPLAY 1

VREF

LED BARGRAPH DISPLAY 2

VREFCOUNTER DAC

PB1 PB3

Selector

CLOCK GENERATOR

COMPARATOR

PB2

Figure 1: Block diagram of a Selectable Timer

The present output voltage of DAC is also fed to either LED Bar-graph 1 or LED Bar-graph 2. The selection can be done by pressing PB2 or PB3.

Pertandingan Kemahiran Malaysia (PKM Ke-22)

PROVIDED MATERIALS

Items Part Name Parts Value

(Model) Quantity

1 Capacitor 0.1uF 10

2 Capacitor 0.47uF 2

3 Capacitor 4.7uF 2

4 Capacitor 47uF 2

5 Resistor 1KΩ 4

6 Resistor 5.1KΩ 4

7 Resistor 100Ω 2

8 Resistor 10 KΩ 8

9 preset 1KΩ 2

10 preset 5KΩ 2

11 555 TIMER 555 Timer 1

12 NAND GATE 4011 1

13 DAC 0808 1

14 4-bit up/down binary counter 40193 2

15 Quad Op-Amp LM324 1

16 JFET Op-Amp LF351 1

17 Quad Bilateral switch 4016 1

18 Dot/Bar Display driver LM3914 2

19 Terminal Block 4-way 1

20 LED bar-graph green 1

21 LED bar-graph red 1

22 Push button (PCB Type) SPST 3


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( ELECTRONICS )

( SOFTWARE DESIGN )

SOALAN PRAKTIKAL

PERINGKAT AKHIR

MASA : 3 JAM

NAMA: _______________________________________

No. KP: _______________________________________




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Project: Software Design Time Limit: 3 hours 1. Project Description

This project is a “Stepper motor control with 2 x 16-segment display”. The block diagram of the project is shown in Figure 1 below. The operational of the board can be indicated by toggling the LED indicator. The stepper motor direction and speed can be controlled by controlling the sequence and interval of pulse applied to the motor. Finally, the alphanumeric display is animated by applying a correct data to the alphanumeric display through the alphanumeric driver.

Figure 1: Block Diagram of Embedded C Programming Module The target board is connected to the MPKM Microcontroller Board as indicated in Figure 2 and the relevant information of the MPKM board is available in Appendix A The related drivers and header files will be provided prior to the competition started.


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c16 b18

n 17

a1

m 2

g8

k 3

r 14

DP

12

s 6

u 5

p 15

h4

f9 e10 d13

t 7

CC

11

DS116_seg

c16 b18

n 17

a1

m 2

g8

k 3

r 14

DP

12

s 6

u 5

p 15

h4

f9 e10 d13

t 7

CC

11

DS216_seg

A1B1C1D1E1F1G1H1

KK1

N1M1

P1

S1R1

T1U1

A2B2C2D2E2F2G2H2

K2

N2M2

P2

S2R2

T2U2

+5V IO +5V IO

IN11IN22IN33

IN44

IN55IN66

IN77

OUT1 16

OUT3 14

OUT4 13

OUT5 12OUT6 11

OUT7 10

OUT2 15

COM 9GND8

U1

ULN2003A

AN 0AN 1AN 2AN 3

+12V

GND

330RR5

D1

+5V IO

IO 16

124 3

S1100nFC3

GND

IO 8

124 3

S3100nFC5

GND

124 3

S2100nFC4

GND

124 3

S4100nFC6

GND

IO 10 IO 11

IO 9

M

B1

Motor Step

+12V

+12V

WXYZ

W

X Y

Z

GND1

SDI2CLK3

LE4

OUT0 5OUT1 6OUT2 7

OUT3 8

OUT4 9OUT5 10

OUT6 11

OUT7 12

OUT8 13OUT9 14

OUT10 15

OUT11 16

OUT12 17OUT13 18

OUT14 19

OUT15 20

OE21

SDO 22

R-EXT23

VDD 24P1

MBI5026CN

GND 1

SDI 2CLK 3

LE 4

OUT05OUT16OUT27

OUT38

OUT49OUT510

OUT611

OUT712

OUT813OUT914

OUT1015

OUT1116

OUT1217OUT1318

OUT1419

OUT1520

OE 21

SDO22

R-EXT 23

VDD24P2

MBI5026CN

470R

R1

500R

R3500R

GND

470R

R2

500R

R4500R

GND

IO 2IO 1

IO 3

IO 0 SDO

IO 2IO 1

IO 3

SDO

+5V IO +5V IO

100nFC1

100nFC2

+5V IO

GNDGND

+5V IO

A1B1C1D1E1F1G1H1KK1

N1M1

P1

S1R1

T1U1

A2B2C2D2E2F2G2H2K2

N2M2

P2

S2R2

T2U2

Figure 2: Target board 2015


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1.1 Requirements

1.1.1 Competitors are able to use simple I/O such switches 1.1.2 Competitors are able to write a program based on built-in TIMER 1.1.3 Competitors are able to write a program based on the 16x16 dot matrix Driver

given. 1.1.4 Competitors are able to manipulate using General Software Function 1.1.5 Competitors are able to design the algorithm suit the problems.

1.2 Tasks

To be provided later

2. Equipment, machinery, installations and materials required

The competitor needs to prepare the following equipment, machinery, installations and materials. No. Material Description Quantity Comment

1 Personal Computer (P4-2GHz,512MB,40Gb) or above 1

2 MPLAB IDE Version 8.9 or above 1

3 MPLAB-C18 Compiler Version 3.10 or above 1

4 MPLAB ICD3 Debugger 1

5 MPKM Pickit Board Standard PIC18F4550 1

6 Target Board 2015 Stepper motor control 1

3. Marking criteria

No. Criteria Description

1 Task A 20%

2 Task B 25%

3 Task C 15%

4 Task D 15%

5 Task E 25%


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Figure 7: Schematic Diagram of Standard MPKM Board

X1

16MHz

C227p

C127p

+5v

C4100n

C3100n

+5v

R110k

RA0/AN02

RA1/AN13

RA2/AN2/VREF-/CVREF4

RA3/AN3/VREF+5

RA4/T0CKI/C1OUT/RCV6

RA5/AN4/SS/LVDIN/C2OUT7

RA6/OSC2/CLKO14

OSC1/CLKI13

RB0/AN12/INT0/FLT0/SDI/SDA33

RB1/AN10/INT1/SCK/SCL34

RB2/AN8/INT2/VMO35

RB3/AN9/CCP2/VPO36

RB4/AN11/KBI0/CSSPP37

RB5/KBI1/PGM38

RB6/KBI2/PGC39

RB7/KBI3/PGD40

RC0/T1OSO/T1CKI 15

RC1/T1OSI/CCP2/UOE 16

RC2/CCP1/P1A 17

VUSB18

RC4/D-/VM 23

RC5/D+/VP 24

RC6/TX/CK 25

RC7/RX/DT/SDO 26

RD0/SPP0 19

RD1/SPP1 20

RD2/SPP2 21

RD3/SPP3 22

RD4/SPP4 27

RD5/SPP5/P1B 28

RD6/SPP6/P1C 29

RD7/SPP7/P1D 30

RE0/AN5/CK1SPP 8

RE1/AN6/CK2SPP 9

RE2/AN7/OESPP 10

RE3/MCLR/VPP 1

U1

PIC18F4550

MCLR

MC

LR

OS

C1

OS

C2

OSC2OSC1

VUSB

C5220n

1 2 3 4 5 6

J166226-006

MC

LR +5V

PG

DP

GC

IO8IO9

IO10IO11IO12

IO13IO14IO15PGMPGCPGD

ANA0ANA1ANA2ANA3T0CKIANA4

IO0IO1IO2IO3IO4IO5IO6IO7

PWM1PWM0

TX/RC6RX/RC7SDOSDA

SCL

SS

PICKIT3

IO16IO17IO18

VI1 VO 3

GN

D2

U27805

C625v/22uF

C725V/22uF

VI1 VO 3

GN

D2

U37805

C1025v/22uF C11

25V/22uF

D1

1N4001

+12v

+12v

0v

C925v/22uF

-12v

D2

1N4001

-12v

+5V

C825V/22uF

+12v +5v io

T1IN11

R1OUT12

T2IN10

R2OUT9

T1OUT 14

R1IN 13

T2OUT 7

R2IN 8

C2+

4

C2-

5

C1+

1

C1-

3

VS+ 2

VS- 6

U4

MAX232

TX/RC6RX/RC7

C13

0.1uF

C140.1uF

C150.1uF

C12

0.1uF

162738495

J3

CONN-D9M

IO0

IO1

IO2

IO3

IO4

IO5

IO6

IO7

IO8

IO9

IO10

IO11

IO12

IO13

IO14

IO15

IO16

IO17

IO18

AN

A0

AN

A1A

NA

2A

NA3

T0C

KI

AN

A4

PWM

1PW

M0

SDA

SCL

SDO

SS

+12v

+5v

io

-12v

+5v

C16100n

Coupling formicrocontroller

Coupling for UART

+12v

-12v

+5v

io

1 2 3 4

50 49 48 475

466

457

448

439

4210

4111

4012

3913

3814

3715

3616

3517

3418

3319

3220

3121

3022

2923

2824

2725

26

J2CONN-DIL50

+5V

T1C

KI

T1CKI

R2680

MC

LR


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Figure 8: Standard MPKM Board I/O Configurations


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PERTANDINGAN WORLDSKILLS MALAYSIA KATEGORI BELIA (WSMB)

TAHUN 2015

(ELECTRONICS) (MFFR)

SOALAN PRAKTIKAL

PERINGKAT AKHIR

MASA : 3 JAM

NAMA: _______________________________________

No. KP: _______________________________________




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Project: Measurement, Fault Finding and Repair Time Limit: 3 Hours Project Description The circuit consist of combination analog and digital circuit to control COUNTER UP/DOWN WITH LED STEP DISPLAY

2.0 CIRCUIT DESCRIPTION 3.1 Refer to appendices for the complete schematic diagram. 3.2 The circuit use a DC power supply +12V, +9V and +5V voltage. 3.3 Upon start up:

a) LED D10 (Green) will turn ON continuously. b) LED D1…D9 (Red) and Display is OFF.

3.4 Upon triggering switch S1:

a) 7 segment display show counting up from 1 to 9 and hold number 9. b) LED D1…D9 (Red) is running starting from LED D1 continuously.

3.5 Retriggering switch S1 after display holding number 9.

a) LED D1…D9 (Red) and Display is OFF.

3.6 Upon triggering switch S2: a) Display counting down from 9 to 1 and hold number 1. b) LED D9…D1 (Red) is running starting from LED D9 continuously.

3.7 Retriggering switch S2 after display holding number 1. a) LED D1…D9 (Red) and Display is OFF.

3.8 The circuit is working prior to the following setting condition: 3.8.1 Varies VR1 to obtain +9V at TP2.


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PARTS LIST

ITEM PART NAME PART VALUE

(MODEL) QUANTITY REFERENCE NUMBER

1 Capacitor 10nF 17 C1, C2, C3, C4, C5, C6, C7, C8, C9, C10, C11, C12, C13, C14, C15, C16, C17

2 Polarized Capacitor (Radial) 47uF 2 C18, C21

3 Polarized Capacitor (Radial) 100uF 2 C19, C24

4 Polarized Capacitor (Radial) 220uF 1 C20

5 Capacitor 100nF 3 C22, C23, C25

6 RED LED LED 3mm 10 D1, D2, D3, D4, D5, D6, D7, D8, D9, D13

7 1 Amp General Purpose Rectifier

Diode 1N4001 3 D10, D11, D12

8

14.2 mm General Purpose Red 7-Segment Display: CC, RH DP, Gray Surface

HDSP-503B 1 DS1

9 Low Voltage Power Supply Connector 1 Power Board

10 General Purpose Transistor NPN Silicon 2N2222 12 Q1, Q2, Q3, Q4, Q5, Q6, Q7, Q8,

Q9, Q10, Q11, Q12

11 Resistor 10K 13 R1, R23, R24, R25, R26, R29, R30, R31, R32, R35, R36, R37, R38

12 Tapped Resistor 10K 1 R2 13 Resistor 1K 2 R3, R4

14 Resistor 220R 10 R5, R6, R7, R8, R9, R10, R11, R12, R13, R39

15 Resistor 150R 7 R14, R15, R16, R17, R18, R19, R20

16 Resistor 4.7K 6 R21, R22, R27, R28, R33, R34 17 Potentiometer 2K 1 R40 18 Resistor 330R 1 R41 19 Switch SW-PB 2 S1, S2

20 Test Point 13 TP1, TP2, TP3, TP4, TP5, TP6, TP7, TP8, TP9, TP10, TP11, TP12, TP13

21 Timer LM555CN 1 U1

22 Dual J-K Master/Slave Flip-Flop with Set and Reset

CD4027BCN 2 U2, U3

23 Dual D-Type Flip-Flop CD4013BCN 2 U4, U8

24 4-Bit Magnitude Comparator HCF4063BEY 2 U5, U6


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25 Quad Exclusive OR Gate, 14-Pin PDIP CD4030CN 1 U7

26 Quad 2-Input OR Buffered B series Gate, 14-Pin PDIP

CD4071BCN 2 U9, U14

27 BCD-to-Decimal Decoder HCC4028BF 1 U10

28 BCD-to-7 Segment Latch/Decoder/Driver CD4511BCN 1 U11

29 Quad 2-Input AND Buffered B series Gate, 14-Pin PDIP

CD4081BCN 4 U12, U13, U15, U16

30 3-Terminal Adjustable Positive Voltage Regulator

LM317T 1 U17

31 Positive Voltage Regulator L7805CP 1 U18

32 DC Adepter 12VDC 2Amp 1 Power Board


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( ELECTRONICS )

( ASSEMBLY )

SOALAN PRAKTIKAL

PERINGKAT AKHIR

MASA : 3 JAM

NAMA: _______________________________________

No. KP: _______________________________________




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Introduction This assembly project will access each competitor’s skill and capacity:

1. Competitor can assemble a product based on the given drawing and instruction. 2. Competitor can complete his product with fully functions.

Description of project and tasks The project assembly is Safe Deposit Box. The heart of the system is a microcontroller PIC 18F2550. The user can enter the desired password and lock the safety deposit box.

Fig 1. Block diagram


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Instructions to the competitor Time limit is 3 hours. 1. Complete this Assembly Project using given materials and document.

1.1 Diagram list

Schematic:

i. Safety deposit box 1.2 Component Layout:

i. Safety deposit box 1.3 Photographs for assembling 1.4 Operation description 1.5 Parts list 1.6 Operation check sheet


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2. Project Description

Front View


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Side View

Bottom View

In unlock mode, user has to enter any 4 combination number appended by * and # to

lock the safe deposit box. Once the safe deposit box locked, the system accepts only the

newest password (previous selected by user) to unlock the safe deposit box. User is

allowed maximum of 3 trials to unlock the safe deposit box. If the wrong password is

entered for more than 3 trials, buzzer is activated and LCD displays ERROR.


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3. Parts List

Item Parts name and value Qt’y

1 SMD TYPE RESISTOR ± 5%

150R 330R 1K 10K

1 5 1 6

2 SMD TYPE CAPACITORS

10uF 1uF 22pF 100nF

5 1 2

10

3 SEMICONDUCTOR COMPONENTS

PIC 18F2550 complete with socket IC FT232R complete with socket ULN2003 Voltage Regulator 7805

1 1 1 2

4 DIODES

Diode 1N5828 (schottkey 1A/20V) LED (5 mm/GREEN) LED (5 mm/RED) LED (5 mm/YELLOW)

1 1 1 1

5 SOCKET AND HEADER

DC Jack socket Terminal Block – DG235-5.0-02P Pickit 3 connector –Header HDR 1 x 6 Connector - IDC Connector 4x2 PIN with Housing (Keypad) Connector - IDC Connector 8x2 PIN with Housing (LCD) Power Supply Connector – Terminal 2 PIN

1 8 1 1 2 2

6 OTHERS

LCD 2 x 16

1


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Crystal 20Mhz completed with socket Trim pot preset 5K PCB type Normally Open PCB Miniature Push Button Switch Reed Switch Adapter 12V DC Buzzer 5Vdc Keypad 3 x 4 Ribbon cable - 16 way 15 c.m Ribbon cable – 7 way 15 c.m Multi core wire 7/0.2 – Black 100 c.m Multi core wire 7/0.2 – Red 100 c.m Multi core wire 7/0.2 – Blue 15 c.m Multi core wire 7/0.2 – Yellow 15 c.m Casing 205mm x 275mm x 110mm METAL Enclosure Rocker Switch – DC 12V PCB Nylon Spacer 15 m.m. Main PCB Sticker M2.5 nut M3 nut

Rubber fit with M4 screw and nut

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 1 1 4 2 8

4. Equipment, machinery, installations and materials required Organizer prepares the following equipment, machinery, installations and materials. Item Qty Material Description Notes

1 1 Worktable with ESD protection

W=1800 , D=900, H=750 [mm]

2 1 Office chair

3 1 Workstation Lamp

4 1 Universal Digital Multi-meter

V, Ω, A, etc


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The competitor needs to prepare the following equipment, machinery, installations and materials. Item Qty Material Description Notes

1 1 Soldering Station

2 1 Solder wick or Solder Remover

3 1 Lead Bender

4 1 Pincer

5 1 Nipper

6 1 Wire Stripper

7 1 Crimping tool

8 1 Scissors

9 1 Tweezers

10 1 IC pick tool

11 1 PCB stand

12 1 Parts box

13 1 Precise screwdriver For trimmer resistor

14 1 Screw driver + type

15 1 Screw driver - type

16 1 Spanner

17 1 Box wrench 5mm, for M3 nut

18 1 Scale 300mm

19 1 Safety Glasses

20 1 Cotton Glove

21 1 ESD wrist strap

22 1 Brush

23 1 Industrial wiper


9

5.1 Power Supply Circuit

5.2 Controller Circuit

12

P1

T/BLOCK 1

D1

Diode 1N5828

GND

100nFC3

100nFC4

GND

+12V

GND GND GND GND

S1

SW-SPST

10uFC2

10uFC1

+12VV_PC

GND

100nFC7

100nFC8

GND GND GND GND

10uFC6

10uFC5

+12VV_IO

IND1

GNDIN1 OUT 3

2

U1

LM7805

GNDIN1 OUT 3

2

U2

O2

O1

TXRX

MCLR

ENRWRSD4D5D6D7

VDD(20)

VSS(8)VSS(19)

100nFC13

GND

20MHz

Y1

22pFC11

22pFC12

O1 O2

GND GND

VUSB

VUSB

12 4

3 S3

10KR6

V_PCMCLR

GND

100nFC14

V_PCVDD(20)

VSS(12)

GND

PICKIT 3

/MCLR/Vpp1

PGD (ICSPDAT)4

PGC (ICSPCLK)5

PGM (LVP)6

GND3

VDD2X2

GND

MCLR

V_PC

PGCPGD

MCLR/VPP/RE31 RA0/AN0 2

RA1/AN1 3

RA2/AN2/VREF-/CVREF 4

RA3/AN3/VREF+ 5

RA4/T0CKI/C1OUT/RCV 6

RA5/AN4/SS/HLVDIN/C2OUT 7

VSS8

OSC1/CLKI9

OSC2/CLKO/RA6 10

RC0/T1OSO/T13CKI 11

RC1/T1OSI/CCP2/UOE 12

RC2/CCP1 13

VUSB14

RC4/D-/VM 15

RC5/D+/VP 16

RC6/TX/CK 17

RC7/RX/DT/SDO 18

VSS19

VDD20

RB0/AN12/INT0/FLT0/SDI/SDA 21

RB1/AN10/INT1/SCK/SCL 22

RB2/AN8/INT2/VMO 23

RB3/AN9/CCP2/VPO 24

RB4/AN11/KBI0 25

RB5/KBI1/PGM 26

RB6/KBI2/PGC 27

RB7/KBI3/PGD 28

U4

PIC18F2550-I/SP

KP_C0KP_C1KP_C2

KP_R0KP_R1KP_R2KP_R3

ErrLockRA5

RB0

BOX

PGCPGD


10

5.3 LCD circuit

VSS

V_PC

VEE

RS RW EN D4

D5

D6

D7

GND

VB+

VB-

VSS

GND

5KRV1

GND

VEE

100nFC10

GND

150RR5

VB+

VB-

GND

V_IO V_IO V_IO

VSS

VDD

VEE

RS RW E D0

D1

D2

D3

D4

D5

D6

D7

VB+

VB-

PROJECT SWDWSMB 2015

X1

LM016L - LCD

5.4 LED indicators

1KR3

330RR4

330RR2

IND1

ERR LOCK

LED - GREEN

D3

LED - RED

D4

LED - YELLOW

D2

GND

V_IO V_IO


11

5.5 FTDI

GND

GND

330RR9

330RR7

330RR8

Virtual Comport

+5V_PC

VUSB 1

D+ 3D- 2

GND 4

COM 5

COM 6

X3

D5 D6 D7

GNDGND

100nFC16

3V3OUT17

OSCO28

OSCI27

NC24

RESET#19

NC8

USBDP15USBDM16 V

CC20

VCCIO

4

TXD 1

RXD 5

RTS# 3

CTS# 11

DTR# 2

DSR# 9

DCD# 10

RI# 6

CBUS0 23

CBUS1 22

CBUS2 13

CBUS3 14

CBUS4 12

AG

ND25

GN

D7

GN

D18

GN

D21

TEST26

U5FT232R

+5V_PC

GND

100nFC17

TXRX

10uFC15

V_IO

5.6 Keypad

KP_C0KP_C1KP_C2KP_R0KP_R1KP_R2KP_R3

KP_R1 KP_R2 KP_R3KP_R0

10KR10

10KR11

10KR12

10KR13

1 2 3

654

0

7 8 9

* #

1234567

V_IO

5.7 Miscellaneous I/O

100nFC9

LS1

Buzzer

GND

S2SW-SPST

10KR1

GND

BOX

Proximity SwitchMUST BE CLOSE TO LOCK

12

P2

PLUNCHERIN11

IN22

IN33

IN44

IN55

IN66

IN77

OUT1 16

OUT3 14

OUT4 13

OUT5 12

OUT6 11

OUT7 10

OUT2 15

COM 9GND8

U3

ULN2003A

BUZZER

PLUNCHERPLUNCHERBUZZER

+12V

+12V+12V

RB0RA5

GND

V_IO


12

5.8 Printed Circuit Board


13

6. Assembly process 6.1 Assemble safety deposit box PCB Assemble the PCB as shown below:

PCB board top view


14

PCB board bottom view


15

6.2 Assemble and wire up circuit referring to the cable length specification as below

Ribbon cable – Keypad

8.5 cm

Ribbon cable - LCD


16

Cable - Reed Switch

Cable - Power tail

Cable – Buzzer


17

Cable – Servo

25.5 cm

Cable – Power switch

Cable – USB


18

Cable – Error indicator (Red)

Cable – Power indicator (Green)


19

6.3 Fix power tail, main switch and USB connector as shown below.


20

6.4 Fix LCD, Keypad and LED indicators as shown below.


21

6.5 Fix Front Panel Fix Front Panels, servo motor, buzzer, reed switch and rubber fit as shown below

Front Panel


22

7. Check the completed assemblies by referring to the operation check sheet below.

Operation Check Sheet: No Operation Keypad LCD YELLOW

LED RED LED GREEN

LED Remark Confirm by

jury 1 Upon power

up 1st Time Ready

Key in PWD pls OFF OFF ON Lid unlock

2 Upon power up

Previous unlocked

Ready Key in PWD pls

OFF OFF ON Lid unlock

3 Upon power up

Previous locked

Locked Key in PWD pls

ON OFF ON Lid locked

4 Upon power up

Previous in Error

Locked Ctc Admin pls

ON ON ON Lid locked

5 To lock Lid open Any 4 number appended with * and #

Ready Close LID


6 To lock Lid closed Any 4 number appended with * and #

Locked You’re protected


7 To unlock Similar PWD to lock (previously) Ready Key in PWD pls


8 To unlock Different PWD to lock (previously) Locked You’re protected


9 To unlock >3 trials Different PWD to lock (previously) Error Ctc Admin pls

ON ON ON Lid locked Buzzer turn on shortly

10 To RESET Press button on reset device

Ready Key in PWD pls


PERTANDINGAN WORLDSKILLS MALAYSIA KATEGORI BELIA · PDF filepertandingan worldskills malaysia...

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